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Yamaha WaveRunner VX 700, Руководство по обслуживанию

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Yamaha WaveRunner VX 700 Скачать руководство пользователя страница 97

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Drive coupling removal and 
installation

1.

Remove the drive coupling.

TIP:

Install the drive coupling with the same spe-
cial service tools that were used for removal.

Flywheel magneto removal and 
installation

1.

Remove the flywheel magneto bolt.

TIP:

Install the bolt with the same special service
tool that was used for removal.

2.

Remove the flywheel magneto. 

NOTICE:

To prevent damage to the engine or
special service tools, screw in the fly-
wheel puller set bolts evenly and com-
pletely so that the puller plate is
parallel to the flywheel magneto.

TIP:

When installing the flywheel magneto,
degrease the flywheel magneto where it is
coupled to the crankshaft.

Drive coupling check

1.

Check the drive coupling. Replace if
damaged or worn.

Flywheel magneto check

1.

Check the ring gear. Replace if damaged
or worn.

Coupler wrench: 90890-06425
Flywheel holder: 90890-06522

Drive coupling:

36 N·m (3.6 kgf·m, 26.6 ft·lb)

Flywheel holder: 90890-06522

Flywheel magneto bolt:

74 N·m (7.4 kgf·m, 54.6 ft·lb)

Flywheel puller: 90890-06521

Starter clutch assy.

Содержание WaveRunner VX 700

Страница 1: ...SERVICE MANUAL WaveRunner F2V 28197 ZN 11 VX 700 VX 700 F2V ...

Страница 2: ...ions and procedures and these are incorporated in successive editions of this manual Also up to date parts information is available on YPEC web Additional information and up to date information on Yamaha products and services are available on Yamaha Service Portal Important information Particularly important information is distinguished in this manual by the following notations The Safety Alert Sy...

Страница 3: ...al information GEN INFO Specification SPEC Maintenance MNT Fuel system FUEL Power unit POWR Jet pump unit JET PUMP Electrical system ELEC Hull and hood HULL HOOD Troubleshooting TRBL SHTG Appendix 1 2 3 4 5 6 7 8 9 A ...

Страница 4: ......

Страница 5: ...ith crane 1 2 Handling of heat gun 1 3 Part lubricant and sealant 1 3 Handling of sealant 1 3 Special service tool 1 3 Tightening torque 1 3 Non reusable part 1 3 Disassembly and assembly 1 4 How to use this manual 1 5 Manual format 1 5 Abbreviation 1 6 Adhesive lubricant sealant and thread locking agent 1 7 Symbol 1 7 Special service tool 1 8 Model feature 1 10 Identification number 1 10 ...

Страница 6: ...resulting in severe injury Hot part During and after operation engine parts are hot enough to cause burns Do not touch any parts in the engine compartment until the engine has cooled Electric shock Do not touch any electrical parts while start ing or operating the engine Otherwise shock or electrocution could result Impeller Do not hold the impeller with your hands when loosening or tightening the...

Страница 7: ...eet by wearing protective gloves and safety shoes when necessary Working with crane When moving the watercraft or when lifting the engine during removal or installation make sure to use a crane with a lifting capacity that is equal to or more than the weight of the watercraft or engine respec tively When lifting the watercraft use the water craft lift harness and make sure that the watercraft is i...

Страница 8: ...n servicing or repairing the watercraft Handling of sealant Wear protective gloves to protect your skin when using the sealants See the material safety data sheet issued by the manufacturer Some of the sealants may be harmful to human health Special service tool Use the recommended special service tools to work safely and to protect parts from dam age Tightening torque Follow the tightening torque...

Страница 9: ... Install bearings so that the bearing identifi cation mark is facing in the direction indi cated in the installation procedure In addition make sure to lubricate the bear ings liberally Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation Check that moving parts operate normally after assembly Safety while working ...

Страница 10: ...ain the details of removal checking and installation where necessary see 5 in the following figure for an example page TIP For troubleshooting procedures see Chapter 9 Troubleshooting 6 6 Impeller duct and drive shaft EPNOC grease AP 0 No Part name Q ty Remarks 1 Bolt 3 M6 20 mm 2 Cap 1 3 O ring 1 Not reusable 4 Cap 1 5 Impeller 1 6 Drive shaft 1 7 Oil seal 1 Not reusable 8 Oil seal 1 Not reusable...

Страница 11: ...Abbreviation Description BOW Bow end CDI Capacitor discharge ignition EX Exhaust IN Intake NMMA National Marine Manufacturers Association PON Pump Octane Number PORT Port side RON Research Octane Number STBD Starboard side STERN Stern end TDC Top Dead Center How to use this manual ...

Страница 12: ...thread lock ing agent and the application points Symbol Name Application Yamaha 2 stroke motor oil Lubricant Water resistant grease Yamaha grease A Lubricant Molybdenum disulfide grease Lubricant Epnoc grease AP 0 Lubricant Symbol Name Application Gasket Maker Sealant LOCTITE 271 red Thread locking agent LOCTITE 242 blue Thread locking agent LOCTITE 572 white Sealant Silicone sealant Sealant Three...

Страница 13: ...ompression gauge 90890 03160 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Coupler wrench 90890 06425 Driver rod L3 90890 06652 Needle bearing attachment 90890 06614 Ball bearing attachment 90890 06634 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Adhesive lubricant sealant and thread locking agent Special service tool ...

Страница 14: ...d LS 90890 06606 Ball bearing attachment 90890 06631 Crankshaft holder 20 90890 06552 Bearing outer race attachment 90890 06628 Drive shaft holder 5 90890 06519 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Ignition tester Spark gap tester 90890 06754 ...

Страница 15: ...serial number The jet pump unit serial number is stamped on a label attached to the intermediate hous ing 1 Jet pump unit name 2 Jet pump unit type 3 Jet pump unit serial number Hull identification number H I N The H I N is stamped on a plate attached to the boarding platform Starting primary I D number F2V 800101 MODEL F2V PRI I D YAMAHA MOTOR CO LTD ASSEMBLED IN U S A FROM AMERICAN AND JAPANESE ...

Страница 16: ...1 11 GEN INFO General information MEMO ...

Страница 17: ...t 2 3 Cylinder head assy 2 3 Crank case assy 2 4 Jet pump unit technical data 2 5 Jet pump unit 2 5 Electrical technical data 2 5 Ignition system 2 5 Charging system 2 6 Control system 2 6 Starting system 2 7 Meter system 2 7 Specified tightening torque 2 8 Fuel system 2 8 Power unit 2 8 Jet pump unit 2 10 Electrical system 2 10 Hull and hood 2 11 General tightening torque 2 12 Cooling system 2 13...

Страница 18: ...aximum fuel consumption L h US gal h lmp gal h 34 0 9 0 7 5 Cruising range h 1 47 Item Unit Model VX 700 Type 2 stroke L2 Cylinder quantity 2 Total displacement cm3 cu in 701 42 8 Bore stroke mm in 81 0 68 0 3 19 2 68 Compression ratio 7 2 1 Intake system Reed valve Starting enrichment Choke valve Scavenging system Loop charge Exhaust system Wet exhaust Lubrication system Oil injection Cooling sys...

Страница 19: ...m Jet thrust nozzle trim angle Degree 3 Item Unit Model VX 700 Fuel type Regular unleaded gasoline Fuel minimum rating PON 86 RON 90 Fuel tank capacity Total L US gal Imp gal 50 13 2 11 0 Reserve L US gal Imp gal 12 3 2 2 6 Engine oil type YAMALUBE 2 W Fuel and oil mixing ratio Wide open throttle 50 1 Engine oil grade NMMA certified TC W3 Oil tank capacity L US gal Imp gal 3 8 1 0 0 8 Item Unit Mo...

Страница 20: ...Low speed screw turns out 5 8 1 4 Throttle valve 190 Valve seat size mm in 1 5 0 06 Arm height mm in 0 0 2 0 0 008 High speed screw turns out 5 8 1 4 front 1 1 8 1 4 rear Throttle lever free play mm in 4 0 7 0 0 16 0 28 Item Unit Model VX 700 Cylinder Minimum compression pressure 1 kPa kgf cm2 psi 590 5 9 84 1 Measuring conditions Ambient temperature 20 C 68 F with spark plugs removed from all cyl...

Страница 21: ...imension height B mm in 1 170 1 190 0 0461 0 0469 Dimension width T mm in 2 750 2 950 0 1083 0 1161 End gap 1 mm in 0 20 0 40 0 008 0 015 Side clearance mm in 0 03 0 05 0 001 0 002 2nd ring Type Keystone Dimension height B mm in 1 170 1 190 0 0461 0 0469 Dimension width T mm in 2 750 2 950 0 1083 0 1161 End gap 1 mm in 0 20 0 40 0 008 0 015 Side clearance mm in 0 03 0 05 0 001 0 002 Connecting rod...

Страница 22: ... 13 2 Drive shaft Runout limit mm in 0 01 0 0004 Intermediate drive shaft Runout limit mm in 0 30 0 012 Nozzle Diameter mm in 86 80 87 40 3 417 3 441 maximum difference of jet thrust nozzle distances mm in 5 0 2 Item Unit Model VX 700 CDI unit Output peak voltage at cranking loaded V 10 at 1500 r min loaded V 200 at 3500 r min loaded V 130 Pickup coil Output peak voltage at cranking unloaded V 5 2...

Страница 23: ...d V 47 3 Resistance 1 at 20 C 68 F Ω 1 143 1 397 Minimum charging current A at r min 14 at 6000 Rectifier regulator Output peak voltage at 3500 r min loaded V 13 0 1 The figures are for reference only Item Unit Model VX 700 Ignition coil Primary coil resistance at 20 C 68 F Ω 0 078 0 106 Secondary coil resistance at 20 C 68 F kΩ 14 336 30 464 Thermoswitch engine Input voltage 1 V 11 0 12 0 Continu...

Страница 24: ...it Seconds 30 Commutator diameter mm in 27 0 28 0 1 06 1 10 Commutator undercut 1 mm in 0 2 0 7 0 008 0 028 Brush length mm in 6 5 12 5 0 26 0 49 1 The figures are for reference only Item Unit Model VX 700 Fuel level sensor Resistance at 20 C 68 F Empty position Ω 757 0 803 0 Full position Ω 0 8 0 Oil level sensor Float distance for continuity mm 37 0 41 0 1 46 1 61 ...

Страница 25: ...11 Cover carburetor 1 screw ø5 4 4 0 44 3 2 4 11 Cover carburetor 2 screw ø5 3 4 0 34 2 5 4 11 Diaphragm cover screw ø5 3 4 0 34 2 5 4 11 Body assy screw ø4 2 0 2 1 5 4 11 Main jet 1 8 0 18 1 3 4 11 Pilot jet 0 7 0 07 0 5 4 11 Air bleed screw ø6 5 0 5 3 7 4 17 Oil pump bolt M6 8 0 8 5 9 4 17 Part to tightened Screw size Tightening torque See page N m kgf m ft lb Coupling cover bolt M6 8 0 8 5 9 5 ...

Страница 26: ...e screw ø4 3 0 3 2 2 5 18 Starter motor bolt M8 18 1 8 13 3 5 25 Starter motor positive lead nut 5 0 5 3 7 5 25 Flywheel cover bolt M6 8 0 8 5 9 5 25 Flywheel magneto bolt M10 74 7 4 54 6 5 25 Drive coupling 36 3 6 26 6 5 25 Base assy screw ø6 8 0 8 5 9 5 25 Engine bracket lower crankcase bolt 1st M10 23 2 3 17 0 5 30 2nd 52 5 2 38 4 5 30 Upper crankcase lower crankcase bolt 1st M8 15 1 5 11 1 5 3...

Страница 27: ... M6 7 0 7 5 2 6 5 Cap bolt M6 8 0 8 5 9 6 6 Impeller M22 75 7 5 55 3 6 6 Transom plate nut 26 2 6 19 2 6 10 Flushing hose nut 5 5 0 55 4 1 6 10 Intermediate housing cover bolt M8 17 1 7 12 5 6 12 Rubber hose clamp 4 0 4 3 0 6 12 Joint bolt M6 7 0 7 5 2 6 12 Driven coupling M24 36 3 6 26 6 6 13 Intermediate drive shaft extension M24 36 3 6 26 6 6 13 Part to tightened Screw size Tightening torque Se...

Страница 28: ...olt M6 7 0 7 5 2 8 13 Steering master assy bolt M8 17 1 7 12 5 8 13 Steering arm assy bolt M8 16 1 6 11 8 8 13 Ball joint nut 7 0 7 5 2 8 14 Ball joint 7 0 7 5 2 8 14 Buzzer bracket bolt M5 4 0 4 3 0 8 14 Case assy bolt M6 7 0 7 5 2 8 14 Steering cable locknut 7 0 7 5 2 8 16 Packing nut 5 9 0 59 4 4 8 16 Seat lock assy bolt M6 6 0 6 4 4 8 18 Projection nut 26 2 6 19 2 8 18 Handgrip nut 5 0 5 3 7 8...

Страница 29: ...vent warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached Unless otherwise indi cated torque specifications require clean dry threads Components should be at room temperature Width across flats A Screw size B General torque specifications N m kgf m ft lb 8 mm M5 5 0 5 3 7 10 mm M6 8 0 8 5 9 12 mm M8 18 1 8 13 3 14 mm M10 36 ...

Страница 30: ...3 Cylinder head 6 Exhaust outer cover 1 Flushing hose Jet pump 7 Water lock Exhaust outlet 5 Exhaust chamber Water To stern outlet To exhaust outlet To pilot outlet 4 Exhaust ring 2 Cylinder block Pilot outlet Stern outlet From flushing hose From jet pump cooling water flow ...

Страница 31: ...ke cable 7 Oil tank breather hose 8 Buzzer lead 9 Multifunction meter lead 0 Left handlebar switch lead A Fuel level sensor lead B Fuel tank breather hose C Oil level sensor lead D Throttle cable E Oil hose F Steering cable G Wiring harness H Spark plug lead 1 I Spark plug lead 2 J Cooling water outlet hose 7 8 6 5 4 3 2 1 J I H G F E D C B A 0 9 Cooling system Cable and hose routing ...

Страница 32: ...eather hose 8 Buzzer lead 9 Multifunction meter lead 0 Left handlebar switch lead A Fuel level sensor lead B Fuel tank breather hose C Oil level sensor lead D Throttle cable E Oil hose F Steering cable G Wiring harness H Spark plug lead 1 I Spark plug lead 2 J Cooling water outlet hose K Fuel inlet hose L Fuel return hose 8 A 6 C 7 D G I H 1 2 J F 4 O 5 E L 0 M K N 9 3 B ...

Страница 33: ...2 16 1 2 3 4 5 6 7 8 9 A M Fuel hose N Fuel reservoir hose O Negative battery cable 8 A 6 C 7 D G I H 1 2 J F 4 O 5 E L 0 M K N 9 3 B Cable and hose routing ...

Страница 34: ...reather hose 8 Buzzer lead 9 Multifunction meter lead 0 Left handlebar switch lead A Fuel level sensor lead B Fuel tank breather hose C Oil level sensor lead D Throttle cable E Oil hose F Steering cable G Wiring harness H Spark plug lead 1 I Spark plug lead 2 J Cooling water outlet hose K Fuel inlet hose L Fuel return hose 9 0 8 7 6 5 G L H I 1 2 4 3 J O K E F B M N D A C ...

Страница 35: ...2 18 1 2 3 4 5 6 7 8 9 A M Fuel hose N Fuel reservoir hose O Negative battery cable 9 0 8 7 6 5 G L H I 1 2 4 3 J O K E F B M N D A C Cable and hose routing ...

Страница 36: ...2 19 SPEC Specification MEMO ...

Страница 37: ...seal check 3 4 Oil tank check 3 4 Check valve check 3 4 Power unit 3 4 Spark plug check 3 4 Compression pressure measurement 3 5 Engine oil level check 3 6 Trolling speed check 3 6 Trolling speed adjustment 3 6 Engine mount check 3 6 Nut and bolt check 3 7 Jet pump unit 3 7 Impeller check 3 7 Water inlet strainer check 3 7 Jet thrust nozzle steering angle check 3 7 Jet thrust nozzle steering angle...

Страница 38: ... 4 Lubrication points Lubricate 3 10 Fuel system Check 3 3 Fuel filter Check 3 3 Check replace 3 3 Fuel tank Check clean 3 3 Oil injection system Check adjust 3 4 Carburetor Check adjust 4 15 Engine idling speed Check adjust 3 6 Carburetor throttle shaft Check 4 14 Water inlet strainer Check clean 3 7 Bilge strainer Clean 3 9 Impeller Check 3 7 Jet thrust nozzle angle Check adjust 3 7 Throttle cab...

Страница 39: ...e play make sure that the throttle cable is not pulled when the handlebar is turned to the right and left 1 Face the handlebar straight ahead 2 Slide the throttle cable end boot 1 to the carburetor pulley end 3 Check that the throttle cable installation length a is within specification 4 If the throttle cable installation length a is out of specification loosen the locknut 2 and then turn the adju...

Страница 40: ...ut When removing fuel system parts wrap them in a cloth and take care that no fuel spills into the engine compartment Fuel filter check 1 Check the fuel filter 1 Replace the fuel filter if cracked or damaged 2 Replace the fuel filter if there are water contaminants and check for water in the fuel tank See Fuel tank check 3 3 Fuel hose check 1 Check the fuel hose Replace if cracked or damaged Fuel ...

Страница 41: ...mpty If the oil tank becomes empty the oil injection pump must be bled to ensure proper oil flow otherwise engine damage may occur See Oil pump air bleeding 4 18 Oil filter check 1 Check the oil filter Clean if there are con taminants Replace if frayed or torn Oil hose oil filler cap and rubber seal check 1 Check the oil hose or oil filler cap Replace if cracked or damaged 2 Check the rubber seal ...

Страница 42: ...top the engine 4 Remove the spark plug caps and then remove the plugs 5 Install the special service tool 1 6 Fully open the throttle lever 7 Crank the engine until the reading on the compression gauge stabilizes 8 Measure the compression pressure for all cylinders according to steps 5 7 9 If the compression pressure is below specification squirt a few drops of engine oil into the cylinder and meas...

Страница 43: ...e is 20 C 68 F or less 3 Connect the special service tool 1 to the spark plug wire 4 Check the trolling speed Trolling speed adjustment 1 Turn the low speed screws 1 until they are lightly seated and then turn out the low speed screws 1 to the specified number of turns 2 Start the engine 3 Turn the throttle stop screw 2 in or out until the specified speed is obtained Engine mount check 1 Check the...

Страница 44: ... installation 6 4 Water inlet strainer check 1 Remove the water inlet strainer cover 1 and water inlet strainer See Jet thrust nozzle impeller duct and impeller hous ing 6 5 2 Check the water inlet strainer mesh a Clean if contaminated Replace if cracked or damaged 3 Install the water inlet strainer mesh a and water inlet strainer cover 1 See Jet thrust nozzle impeller duct and impeller housing 6 ...

Страница 45: ...mp end 8 17 8 Install the service lid See Front hood 8 8 Electrical Battery check Battery electrolyte is poisonous and dan gerous causing severe burns etc Elec trolyte contains sulfuric acid Avoid contact with skin eyes or clothing Antidotes External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physi cian immediatel...

Страница 46: ...ed water until the level is between the maximum level mark b and minimum level mark a 4 Check the specific gravity of the electro lyte Charge the battery if below specifi cation 5 Install the battery 5 and then install the bands 4 6 Connect the battery breather hose 3 NOTICE Make sure that the battery breather hose 3 is properly con nected and is not obstructed 7 Connect the positive battery cable...

Страница 47: ...le handlebar end TIP Before lubricating the throttle cable squeeze the throttle lever and then remove the rubber seal 1 2 Lubricate the throttle cable carburetor end 3 Lubricate the choke cable carburetor end Nozzle pivot shaft and steering cable lubrication 1 Lubricate the nozzle pivot shaft and steering cable Steering cable and steering cable joint lubrication 1 Lubricate the steering cable and ...

Страница 48: ...3 11 MNT Maintenance TIP Disconnect the joint and apply a small amount of grease Recommended lubricant Yamaha grease A ...

Страница 49: ...able and throttle cable installation 4 10 Carburetor assy check 4 10 Carburetor and fuel pump 4 11 Diaphragm check 4 14 Arm check 4 14 Body assy check 4 14 Needle valve check 4 14 Jet and carburetor body check 4 14 Fuel pump check 4 15 Fuel filter check 4 15 High and low speed screw adjustment 4 15 Throttle valve synchronization check and adjustment 4 15 Choke valve synchronization check and adjus...

Страница 50: ...ilter No Part name Q ty Remarks 1 Screw 1 M4 7 mm 2 Fuel cock knob 1 3 Nut 1 4 Washer 1 5 Fuel cock assy 1 6 Fuel hose 3 7 Holder 1 8 Fuel filter 1 9 Fuel hose 1 1 2 7 8 9 3 4 5 6 OUT ON RES 2 N m 0 2 kgf m 1 5 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib ...

Страница 51: ... Fuel system 3 3 Fuel cock check Before checking the fuel system remove the battery and then remove the fuel filler cap to reduce any pressure inside the fuel tank 1 Check the fuel cock Replace if there is rough movement Fuel cock and fuel filter ...

Страница 52: ...4 3 FUEL Fuel system Choke cable No Part name Q ty Remarks 1 Screw 1 M3 6 mm 2 Knob 1 3 Friction adjusting nut 1 4 Nut 1 5 Choke cable 1 2 3 5 4 1 2 N m 0 2 kgf m 1 5 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib ...

Страница 53: ...r seal 1 5 Tank belt 1 6 Oil level sensor coupler 1 7 Oil level sensor 1 8 Oil filter 1 9 Damper 1 10 Clamp 1 11 Oil filler hose 1 12 Breather hose 1 13 Oil hose 1 14 Oil tank 1 15 Damper 1 2 1 3 4 11 12 14 13 15 10 6 7 8 9 3 7 N m 0 37 kgf m 2 7 ft Ib 5 VENT 6 N m 0 6 kgf m 4 4 ft Ib Choke cable Oil tank ...

Страница 54: ... if frayed or teared 2 Check the rubber seal Replace if cracked or worn 3 Check the hoses Replace if cracked or damaged 4 Check the oil tank filler cap Replace if cracked or damaged Oil level sensor check See Indication system 7 15 Oil tank check 1 Check the oil tank Replace if cracked or damaged ...

Страница 55: ...ler hose 1 6 Fuel tank breather hose 1 7 Check valve 1 8 Fuel tank breather hose 1 9 Fuel level sensor coupler 1 10 Fuel hose 3 11 Tank belt 1 12 Fuel tank 1 13 Clamp 1 14 Fuel level sensor assy 1 ON RETURN RES VENT VENT 6 8 10 7 5 4 3 2 1 14 13 12 1 9 3 7 N m 0 37 kgf m 2 7 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 11 Oil tank Fuel tank ...

Страница 56: ...nd a is restricted Replace if the air flow is unrestricted È Upright É Inverted Fuel level sensor check See Indication system 7 15 Fuel tank check 1 Check the fuel tank Replace if cracked or damaged Fuel filler cap check 1 Install the fuel filler cap 1 onto the fuel filler neck 2 and then hold the fuel filler neck 2 2 Turn the fuel filler cap 1 clockwise È and check that it clicks when tightened c...

Страница 57: ... Bolt 1 M6 14 mm 7 Bolt 1 M6 12 mm 8 Holder 1 9 Washer 1 10 Bolt 6 M6 20 mm 11 Flame arrester holder 1 12 Gasket 1 Not reusable 13 Plate 1 14 Gasket 1 Not reusable 15 Choke cable 1 a 13 15 mm 0 51 0 59 in 1 N m 0 1 kgf m 0 7 ft Ib 7 9 8 6 5 4 14 17 19 18 17 22 17 20 23 16 21 15 3 3 2 1 10 11 4 5 12 13 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib Fuel tank Carbure...

Страница 58: ... Not reusable 18 Fuel hose 1 19 Pulse hose 1 20 Fuel reservoir hose 1 21 Nut 4 22 Carburetor assy 1 23 Gasket 1 Not reusable 1 N m 0 1 kgf m 0 7 ft Ib 7 9 8 6 5 4 14 17 19 18 17 22 17 20 23 16 21 15 3 3 2 1 10 11 4 5 12 13 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib ...

Страница 59: ... specified torque 2 Adjust the throttle lever free play See Steering system 3 2 Carburetor assy check 1 Adjust the trolling speed See Power unit 3 4 Choke cable and throttle cable guide installation position a 14 0 1 0 mm 0 55 0 04 in Choke cable nut b 8 N m 0 8 kgf m 5 9 ft lb Throttle cable nut c 8 N m 0 8 kgf m 5 9 ft lb 1 b c 2 a Carburetor unit ...

Страница 60: ...ve seat 2 9 Diaphragm 1 10 Packing 1 11 Fuel filter 1 12 Screw 4 M5 18 mm 13 Cover 1 14 Packing 1 15 Fuel filter 1 1 8 N m 0 18 kgf m 1 3 ft Ib 0 7 N m 0 07 kgf m 0 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 2 0 N m 0 2 kgf m 1 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 4 4 N m 0 44 kgf m 3 2 ft Ib 43 32 34 35 33 36 42 19 21 22 20 11 10 31 28 29 30 37 38 39 ...

Страница 61: ...7 Washer 2 28 Screw 8 M5 12 mm 29 Cover 2 30 Diaphragm 2 31 Screw 2 M3 6 mm 1 8 N m 0 18 kgf m 1 3 ft Ib 0 7 N m 0 07 kgf m 0 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 2 0 N m 0 2 kgf m 1 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 4 4 N m 0 44 kgf m 3 2 ft Ib 43 32 34 35 33 36 42 19 21 22 20 11 10 31 28 29 30 37 38 39 40 41 24 25 26 27 23 9 6 8 7 5 4 3 2 1 ...

Страница 62: ...or 2 F 120 41 Pilot jet 2 67 5 42 Carburetor assy 1 1 43 Carburetor assy 2 1 1 8 N m 0 18 kgf m 1 3 ft Ib 0 7 N m 0 07 kgf m 0 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 2 0 N m 0 2 kgf m 1 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 4 4 N m 0 44 kgf m 3 2 ft Ib 43 32 34 35 33 36 42 19 21 22 20 11 10 31 28 29 30 37 38 39 40 41 24 25 26 27 23 9 6 8 7 5 4 3 2 1...

Страница 63: ...ged 2 Check the valve clear film 1 Replace if damaged TIP Always replace the body assy and valve clear film as a set Needle valve check 1 Clean the needle valve assy and then check the needle valve assy Replace if worn a TIP Always replace the needle valve and needle valve seat as a set Jet and carburetor body check Do not use a steel wire to clean the jets This may enlarge the jet diameters and s...

Страница 64: ...he opening angle of both throttle valves is the same 2 Turn out the idle adjusting screw 1 until its tips are no longer touching the throttle cable pulley 2 TIP Record the set position of the idle adjusting screw 3 Check that the throttle valve of the Car buretor 1 rear 3 is fully closed 4 Turn the synchronization screw 4 in or out until the throttle valve of the Carbure tor 2 front 5 is fully clo...

Страница 65: ...4 16 1 2 3 4 5 6 7 8 9 A Carburetor assy check 1 Adjust the trolling speed See Power unit 3 4 Carburetor and fuel pump ...

Страница 66: ...3 35 in 5 Oil delivery hose 1 1 70 mm 2 76 in 6 Bolt 2 M6 35 mm 7 Oil pump 1 8 Gasket 1 Not reusable 9 Hose clamp 4 10 Check valve 2 11 Oil delivery hose 2 1 210 mm 8 27 in 12 Oil delivery hose 2 1 450 mm 17 72 in 7 1 2 9 9 9 9 8 6 5 4 3 3 10 10 12 11 6 LT 572 LT LT 572 LT 8 N m 0 8 kgf m 5 9 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib ...

Страница 67: ...flow from the end a is restricted Replace if the airflow is unrestricted Oil pump air bleeding Do not run the engine if oil does not flow out of the air bleed screw Inspect the oil hose for proper routing and make sure there are no restrictions in the line 1 Place rags around the air bleed screw 1 to catch any oil that might spill 2 Fill the oil tank with the recommended oil TIP If the oil pump is...

Страница 68: ...nstallation 5 17 Cylinder 5 18 Cylinder check 5 19 Cylinder installation 5 19 Pistons 5 21 Piston pin clip removal and installation 5 22 Piston check 5 22 Piston ring check 5 22 Piston pin and bearing check 5 23 Piston installation 5 23 Flywheel magneto and base assy 5 25 Starter clutch assy 5 27 Drive coupling removal and installation 5 28 Flywheel magneto removal and installation 5 28 Drive coup...

Страница 69: ...1 2 3 4 5 6 7 8 9 A Crankcase 5 30 Crankcase check 5 32 Crankcase installation 5 32 Crankshaft 5 33 Crankshaft check 5 34 ...

Страница 70: ...x 1 6 Band cooling water hose 1 1 È Cooling water pilot outlet 7 Band cooling water hose 1 1 8 Clamp cooling water hose 1 1 É Cooling water outlet 9 Clamp 1 10 Band oil hose 1 1 11 Band fuel hose 2 2 12 Choke cable 1 13 Throttle cable 1 11 7 9 18 11 12 13 10 2 17 1 6 16 8 15 14 5 4 3 14 LT 572 LT LT 271 5 N m 0 5 kgf m 3 7 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 17 N m 1 7 kgf m ...

Страница 71: ...mm 15 Coupling cover 1 16 Bolt washer 4 4 M8 35 mm 17 Shim 18 Engine unit 1 11 7 9 18 11 12 13 10 2 17 1 6 16 8 15 14 5 4 3 14 LT 572 LT LT 271 5 N m 0 5 kgf m 3 7 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib Engine unit ...

Страница 72: ...r unit Engine mount No Part name Q ty Remarks 1 Bolt 8 M8 35 mm 2 Engine mount 4 3 Bolt 4 4 Bracket 1 5 Bracket 1 6 Bracket 2 BOW 17 N m 1 7 kgf m 12 5 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 1 1 2 4 6 2 2 6 1 3 1 2 3 5 1 ...

Страница 73: ...cou plers 1 and then remove the plastic ties 2 4 Remove the wiring harness from the plastic ties 3 5 Remove the electrical box 4 and plastic ties 5 6 Remove the band 6 and then discon nect the cooling water hose 7 7 Remove the band 8 and then discon nect the cooling water hose 9 8 Disconnect the cooling water hose 0 from hose joint A 9 Disconnect the exhaust hose B from the water lock 10 Remove th...

Страница 74: ... H 13 Remove the fuel hose H from the plastic ties I 14 Disconnect the throttle cable J and choke cable K 15 Remove the coupling cover L 16 Loosen the engine mounting bolts M 17 Lift the engine unit slightly remove the shims N and then lower the unit TIP Make a note of the position of each removed shim so that it can be installed in its original position 18 Remove the engine mounting bolts M and w...

Страница 75: ...sure to check the coupling clearance Engine unit installation When installing the engine unit take care to avoid causing damage to the hull liner and deck opening 1 Move the engine unit rearward to con nect the coupling 1 and then lower the unit onto the engine mounts TIP Do not install the rubber damper until the coupling clearance adjustment has been made 2 Temporarily install the engine mountin...

Страница 76: ...thin specification Readjust if out of specification 12 Install the coupling cover 6 and collar 7 and then tighten the bolt 8 to the specified torque 13 Connect the throttle cable 9 and choke cable 0 14 Check the throttle cable installation length c and choke cable installation length c is within specification and then tighten the nuts to the specified torque Clearance a Less than 1 0 mm 0 039 in w...

Страница 77: ...t the cooling water hose H to hose joint I 20 Connect the exhaust hose J 21 Connect the cooling water hose K and then install the band L 22 Connect the cooling water hose M and then install the band N Choke cable and throttle cable guide installation position c 14 0 1 0 mm 0 55 0 04 in Choke cable nut d 8 N m 0 8 kgf m 5 9 ft lb Throttle cable nut e 8 N m 0 8 kgf m 5 9 ft lb 0 d e 9 c A C B D E G ...

Страница 78: ... ties R 26 Connect the multifunction meter couplers S and then install the plastic ties T 27 Install the service lid 28 Connect the positive battery cable and then connect the negative battery cable 29 Coat the battery cable terminals and bat tery terminals with water resistance grease Electrical box nut P 15 N m 1 5 kgf m 11 1 ft lb O Q P R T T S ...

Страница 79: ...3 Clamp 1 4 Bolt 2 M8 75 mm 5 Bolt 2 M8 115 mm 6 Exhaust ring 1 7 Dowel pin 2 8 Gasket 1 Not reusable 9 Clamp 1 10 Joint 1 11 Exhaust joint 1 2 N m 0 2 kgf m 1 5 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 29 N m 2 9 kgf m 21 4 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 11 2 2 1 1 1 5 4 8 7 6 9 10 3 Engine mount Exhaust ring ...

Страница 80: ...ot reusable 3 Joint 1 4 Hose 1 5 Hose 1 6 Bolt 2 M10 35 mm 7 Bolt 4 M10 45 mm 8 Muffler stay 1 9 Bolt 2 M10 35 mm 10 Exhaust chamber assy 1 2 N m 0 2 kgf m 1 5 ft Ib 46 N m 4 6 kgf m 33 9 ft Ib 2 5 2 N m 0 2 kgf m 1 5 ft Ib 39 N m 3 9 kgf m 28 8 ft Ib 3 6 2 N m 0 2 kgf m 1 5 ft Ib 39 N m 3 9 kgf m 28 8 ft Ib 1 4 6 7 8 5 2 2 3 2 4 2 9 10 1 ...

Страница 81: ...Exhaust outer cover 1 1 3 Gasket 1 Not reusable 4 Exhaust inner cover 1 5 Rubber seal 1 6 Gasket 1 Not reusable 7 Bolt 6 M6 25 mm 8 Exhaust outer cover 2 1 9 Gasket 1 Not reusable 10 Exhaust chamber 1 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib Exhaust chamber assy Exhaust chamber ...

Страница 82: ...y Remarks Exhaust chamber See Exhaust chamber assy 5 11 1 Clamp cooling water hose 1 1 È Cooling water inlet 2 Bolt 8 M10 35 mm 3 Muffler 1 4 Gasket 1 Not reusable LT 271 LT 271 4 3 1 2 È 21 N m 2 1 kgf m 15 5 ft Ib 39 N m 3 9 kgf m 28 8 ft Ib 1 2 ...

Страница 83: ...mm 2 Plate 1 3 Bolt 8 M6 25 mm 4 Bolt 3 M6 35 mm 5 Intake manifold 1 6 Screw 4 M5 15 mm 7 Reed valve assy 2 8 Plate 1 9 Gasket 2 Not reusable 10 Screw 16 M3 8 mm 11 Valve stopper 8 12 Reed valve 8 1 N m 0 1 kgf m 0 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib Muffler Reed valves ...

Страница 84: ...reed valves Replace if cracked or damaged 2 Measure the valve warpage a Replace if out of specification 3 Measure the valve stopper height b Replace if out of specification Valve warpage limit 0 2 mm 0 01 in Valve stopper height 8 8 9 2 mm 0 35 0 36 in ...

Страница 85: ... assy See Exhaust chamber assy 5 11 1 Bolt 2 M6 16 mm 2 Thermoswitch 1 3 Spark plug 2 4 Bolt 10 M8 50 mm 5 Cylinder head 1 6 Gasket 1 25 N m 2 5 kgf m 18 4 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 29 N m 2 9 kgf m 21 4 ft Ib 1 2 4 3 5 6 8 N m 0 8 kgf m 5 9 ft Ib Reed valves Cylinder head ...

Страница 86: ...mineral deposits 3 Measure the cylinder head warpage Resurface if out of specification or if there are score marks TIP Place 400 600 grit wet sandpaper on a sur face plate and resurface the cylinder head using a figure eight sanding pattern Cylinder head installation 1 Install the cylinder head and then tighten the bolts to the specified torque in the order 1 2 and so on Warpage limit 0 1 mm 0 004...

Страница 87: ...ylinder head See Cylinder head 5 16 1 Bolt 4 M10 40 mm 2 Bolt 2 M10 55 mm 3 Cylinder 1 4 Gasket 1 Not reusable 5 Dowel pin 2 6 Screw 1 M4 12 mm 7 Anode 1 3 N m 0 3 kgf m 2 2 ft Ib 22 N m 2 2 kgf m 16 2 ft Ib 39 N m 3 9 kgf m 28 8 ft Ib 1 2 Cylinder head Cylinder ...

Страница 88: ...the cylinder and piston as a set if out of specification TIP Measure the cylinder bore parallel to and at a right angle to the crankshaft Then average the measurements Cylinder installation 1 Install the cylinder and then tighten the bolts to the specified torque in the order 1 2 and so on Standard Limit Cylinder bore D 81 000 81 020 mm 3 1890 3 1898 in 81 100 mm 3 1929 in Taper T 0 080 mm 0 0031 ...

Страница 89: ...5 20 1 2 3 4 5 6 7 8 9 A Cylinder bolt 1st 22 N m 2 2 kgf m 16 2 ft lb 2nd 39 N m 3 9 kgf m 28 8 ft lb 6 2 3 5 1 4 Cylinder ...

Страница 90: ...5 21 POWR Power unit Pistons No Part name Q ty Remarks Cylinder See Cylinder 5 18 1 Piston pin clip 4 Not reusable 2 Piston pin 2 3 Piston 2 a Arrow mark 4 Washer 4 5 Bearing 2 6 Piston ring 4 ...

Страница 91: ... piston wall in a crisscross pattern 3 Measure the piston skirt diameter Replace if out of specification Piston ring check 1 Measure the side clearance using a thickness gauge 1 Replace the piston and piston rings as a set if out of specifi cation 2 Measure the end gap using a thickness gauge 1 Replace the piston rings as a set if out of specification TIP Push the piston ring into the cylinder wit...

Страница 92: ...free play at the small end of the connecting rod as shown Replace the piston pin crank shaft assy small end bearing or all parts if there is free play or wear at the small end Piston installation Align each end gap with its respective locating pin 1 Install the top ring and 2nd ring TIP Install the piston rings with the recess for the locating pin facing up toward the piston crown 2 Assemble the b...

Страница 93: ...5 24 1 2 3 4 5 6 7 8 9 A TIP Install the piston with the arrow a facing towards the exhaust port Do not align the open end of the clip with the piston pin slot b Pistons ...

Страница 94: ...et 1 Not reusable 4 Dowel pin 2 5 Drive coupling 1 6 Bolt 1 M10 32 mm 7 Flywheel magneto 1 8 Woodruff key 1 9 Starter clutch assy 1 10 Screw 2 M6 16 mm 11 Base assy 1 12 Nut washer 1 1 13 Starter motor lead 1 5 N m 0 5 kgf m 3 7 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 36 N m 3 6 kgf m 26 6 ft Ib 74 N m 7 4 kgf m 54 6 ft Ib 1207D 1207D ...

Страница 95: ...arks 14 Bolt 2 M6 16 mm 15 Starter motor 1 5 N m 0 5 kgf m 3 7 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 36 N m 3 6 kgf m 26 6 ft Ib 74 N m 7 4 kgf m 54 6 ft Ib 1207D 1207D Flywheel magneto and base assy ...

Страница 96: ...ower unit Starter clutch assy No Part name Q ty Remarks 1 Clip 1 Not reusable 2 Clip stopper 1 3 Spring seat 1 4 Spring 1 5 Washer 1 6 Idle gear 1 7 Circlip 1 8 Plate 1 9 Weight 3 10 Spring ring 1 11 Pinion gear 1 ...

Страница 97: ...ecial service tools screw in the fly wheel puller set bolts evenly and com pletely so that the puller plate is parallel to the flywheel magneto TIP When installing the flywheel magneto degrease the flywheel magneto where it is coupled to the crankshaft Drive coupling check 1 Check the drive coupling Replace if damaged or worn Flywheel magneto check 1 Check the ring gear Replace if damaged or worn ...

Страница 98: ... damaged or worn 2 Check the idle gear 2 Replace if dam aged or worn 3 Check the gear movement Replace the defective part s if there is rough move ment Base assy installation 1 Install the base assy 1 Distance a 0 1 mm 0 0 04 in Base assy screw 2 8 N m 0 8 kgf m 5 9 ft lb 2 1 a 1207D ...

Страница 99: ...3 Bolt 1 M10 70 mm 4 Bolt 1 M10 80 mm 5 Engine bracket 1 6 Bolt 3 M10 70 mm 7 Engine bracket 1 8 Bolt 4 M8 83 mm 9 Rubber mount 1 10 Bolt 4 M8 85 mm 11 Lower crankcase 1 12 Dowel pin 2 23 N m 2 3 kgf m 17 0 ft Ib 52 N m 5 2 kgf m 38 4 ft Ib 1 2 15 N m 1 5 kgf m 11 1 ft Ib 27 N m 2 7 kgf m 19 9 ft Ib 1 2 23 N m 2 3 kgf m 17 0 ft Ib 52 N m 5 2 kgf m 38 4 ft Ib 1 2 Starter clutch assy Crankcase ...

Страница 100: ... Q ty Remarks 13 Crankshaft assy 1 14 Upper crankcase 1 23 N m 2 3 kgf m 17 0 ft Ib 52 N m 5 2 kgf m 38 4 ft Ib 1 2 15 N m 1 5 kgf m 11 1 ft Ib 27 N m 2 7 kgf m 19 9 ft Ib 1 2 23 N m 2 3 kgf m 17 0 ft Ib 52 N m 5 2 kgf m 38 4 ft Ib 1 2 ...

Страница 101: ...faces 2 Install the crankshaft TIP Install the bearing location pins into the grooves in the crankcase body Make sure that the crankshaft rotates smoothly after installing it 3 Install the crankcase and rubber mount and then tighten the bolts to the specified torque in the order 1 2 and so on TIP Be sure that the F mark a is on the fly wheel magneto side Crankcase bolt 1st 15 N m 1 5 kgf m 11 1 ft...

Страница 102: ...unit Crankshaft No Part name Q ty Remarks Crankcase See Crankcase 5 30 1 Oil seal 1 Not reusable 2 Bearing 1 3 Oil seal 1 2 Not reusable 4 Drive shaft collar 1 5 Bearing clip 1 6 Bearing 2 1 7 Crankshaft assy 1 7 5 6 4 ...

Страница 103: ...ee play d using a dial gauge Replace if out of specifica tion 5 Check the bearings Replace if damaged or pitted TIP Before checking the bearings thoroughly clean them Immediately after checking the bearings lubricate them to prevent rust 6 Check the oil seals Replace if damaged or worn Crank width a 61 950 62 000 mm 2 4390 2 4409 in Deflection limit b 0 050 mm 0 0020 in Big end side clearance c 0 ...

Страница 104: ...5 35 POWR Power unit MEMO ...

Страница 105: ...aft installation 6 8 Transom plate and hoses 6 10 Bilge strainer check 6 11 Bilge hose check 6 11 Cooling water hose check 6 11 Bearing housing 6 12 Intermediate drive shaft assy 6 13 Joint removal 6 14 Joint installation 6 14 Driven coupling removal and installation 6 15 Intermediate drive shaft extension removal 6 15 Intermediate drive shaft removal 6 15 Bearing removal 6 15 Driven coupling chec...

Страница 106: ...ate No Part name Q ty Remarks 1 Bolt 2 M6 30 mm 2 Bolt 2 M10 25 mm 3 Intake grate 1 4 Screw 4 M5 12 mm 5 Cover 1 6 Bolt 4 M8 35 mm 7 Ride plate 1 4 N m 0 4 kgf m 3 0 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 40 N m 4 0 kgf m 29 5 ft Ib ...

Страница 107: ...2 Bolt 2 M8 18 mm 13 Bolt 4 M10 45 mm 14 Jet pump unit 1 15 Dowel pin 2 16 Bolt 2 M8 24 mm 10 6 5 4 2 15 2 11 LT 572 LT 572 LT 572 LT 572 LT 242 LT 271 LT 3 16 17 18 16 17 18 19 13 1 9 12 7 8 14 4 1 N m 0 1 kgf m 0 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 6 8 N m 0 68 kgf m 4 9 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 14 N m 1 4 kgf m 10 3 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 40 N m 4 0 kgf...

Страница 108: ... 11 LT 572 LT 572 LT 572 LT 572 LT 242 LT 271 LT 3 16 17 18 16 17 18 19 13 1 9 12 7 8 14 4 1 N m 0 1 kgf m 0 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 6 8 N m 0 68 kgf m 4 9 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 14 N m 1 4 kgf m 10 3 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 40 N m 4 0 kgf m 29 5 ft Ib ...

Страница 109: ...e the battery before installing the jet pump unit 1 Clean the mating surfaces of the jet pump unit 1 and transom plate 2 2 Apply sealant to the mating surfaces of the jet pump unit 1 and transom plate 2 3 Install the jet pump unit 1 and then tighten the bolts 3 4 and 5 to the specified torques 2 a 1 a a 2 1 2 1 È É Jet pump unit assy bolt M10 45 mm 3 40 N m 4 0 kgf m 29 5 ft lb Jet pump unit assy ...

Страница 110: ...10 125 mm 5 Bracket 1 6 Nozzle 1 7 Impeller duct assy 1 8 Impeller housing 1 1 9 Pin 2 10 Bolt 4 M6 35 mm 11 Water inlet cover 1 12 Packing 1 13 Water inlet strainer 1 14 Packing 1 10 11 12 13 14 9 9 7 LT 572 LT LT 572 LT LT 572 LT 8 1 2 3 4 4 6 5 LT 271 A A 7 N m 0 7 kgf m 5 2 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 40 N m 4 0 kgf m 29 5 ft Ib 40 N m 4 0 kgf m 29 5 ft Ib ...

Страница 111: ...3 M6 20 mm 2 Cap 1 3 O ring 1 Not reusable 4 Cap 1 5 Impeller 1 6 Drive shaft 1 7 Oil seal 1 Not reusable 8 Oil seal 1 Not reusable 9 Rear bearing 1 Not reusable 10 Spacer 1 11 Front bearing 1 Not reusable 12 Impeller duct 1 Jet thrust nozzle impeller duct and impeller housing Impeller duct and drive shaft ...

Страница 112: ...e rear bearing 4 Remove the oil seals TIP Remove the oil seals using a flat head screw driver 5 Remove the front bearing TIP Remove the front bearing using a press Impeller check 1 Check the impeller Replace if damaged Crankshaft holder 20 90890 06552 a a 1 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 Driver rod L3 90890 06652 Needle bearing a...

Страница 113: ...rear bearing TIP Install the rear bearing onto the drive shaft using a press Press the rear bearing using a pipe of the proper size more than 140 mm 5 51 in long and that has an inner diameter of 26 mm 1 02 in 3 Install the spacer 4 Add a EPNOC grease AP 0 between the drive shaft and spacer Impeller housing inside diameter a 155 35 155 45 mm 6 116 6 120 in Drive shaft runout limit 0 01 mm 0 0004 i...

Страница 114: ...ng spacer and rear bearing TIP Press the rear bearing using a washer or pipe of the proper size outer diameter of 50 mm 1 97 in and an inner diameter of 33 mm 1 30 in 7 Add a EPNOC grease AP 0 into the cap 8 Install the impeller TIP Hold the impeller duct assembly in a vise between two aluminum plates a Quantity 20 g 0 7 oz Distance a 11 7 0 2 mm 0 46 0 01 in a Quantity 20 g 0 7 oz Impeller 75 N m...

Страница 115: ...t pump unit assy See Jet pump unit 6 2 1 Clamp 1 2 Bilge hose 1 1 3 Clamp 1 4 Cooling water hose 1 Cooling water inlet 5 Bilge strainer 1 6 Nut washer 2 2 7 Nut washer 2 2 8 Transom plate 1 9 Bilge hose 2 1 5 5 N m 0 55 kgf m 4 0 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib Impeller duct and drive shaft Transom plate and hoses ...

Страница 116: ... Jet pump unit Bilge strainer check See Hull and hood 3 9 Bilge hose check 1 Check the bilge hoses Replace if cracked or damaged Cooling water hose check 1 Check the cooling water hoses Replace if cracked or damage ...

Страница 117: ... Rubber coupling 1 2 Bolt 4 M8 48 mm 3 Intermediate housing cover 1 4 Clamp 2 5 Intermediate drive shaft assy 1 6 Rubber hose 1 7 Bolt 3 M6 14 mm 8 Joint 1 2 3 4 6 5 1 LT 271 7 7 7 8 4 N m 0 4 kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib Transom plate and hoses Bearing housing ...

Страница 118: ...Q ty Remarks 1 Driven coupling 1 2 Washer 1 3 Damper 1 4 Intermediate drive shaft extension 1 5 Intermediate drive shaft 1 6 Circlip 1 Not reusable 7 Oil seal 1 Not reusable 8 Bearing 1 Not reusable 9 Oil seal 1 Not reusable 10 Oil seal 1 Not reusable 11 Bearing housing 1 ...

Страница 119: ... TIP When using the heat gun be careful not to direct the heat towards any hoses or rubber parts After removing the joint clean off any adhe sive remaining on the hull Joint installation 1 Apply urethane adhesive 1 MWV GLUET UB to the hull in the area shown in the illustration using the glue gun 2 MWV GLUEG UN and then install the joint TIP Before installing the joint clean the contact surfaces of...

Страница 120: ...aft holder and inter mediate drive shaft are properly engaged Intermediate drive shaft extension removal 1 Remove the intermediate drive shaft extension TIP Fit a wrench into the notches in the inter mediate drive shaft extension Check that the drive shaft holder and inter mediate drive shaft are properly engaged Intermediate drive shaft removal 1 Remove the intermediate drive shaft TIP Remove the...

Страница 121: ...termediate drive shaft TIP Install the intermediate drive shaft using a press Intermediate drive shaft extension installation 1 Install the intermediate drive shaft exten sion Driver rod LS 90890 06606 Bearing outer race attachment 90890 06628 Driver rod LS 90890 06606 Ball bearing attachment 90890 06631 Distance a 14 2 0 2 mm 0 56 0 01 in Driver rod LS 90890 06606 Ball bearing attachment 90890 06...

Страница 122: ...6 17 JET PUMP Jet pump unit TIP Fit a wrench into the notches in the interme diate drive shaft extension Intermediate drive shaft extension 36 N m 3 6 kgf m 26 6 ft lb ...

Страница 123: ...tem 7 9 Lighting coil 7 9 Rectifier regulator 7 9 Starting system 7 10 Fuse 7 10 Left handlebar switch assy 7 10 Starter relay 7 11 Starter motor 7 12 Starter motor operation 7 13 Armature 7 13 Front and rear cover 7 14 Brush holder 7 14 Starter motor assembly 7 14 Indication system 7 15 Multifunction meter 7 15 Oil level sensor and oil level warning indicator 7 15 Fuel level meter display and fue...

Страница 124: ...s 4 Electrical box rectifier regulator CDI unit starter relay and ignition coil 5 Battery 6 Starter motor 7 Thermoswitch 8 Lighting coil pickup coil and charge coil 9 Fuel level sensor 0 Left handlebar switch assy Engine stop switch engine shut off switch and start switch A Buzzer 5 4 2 3 1 A 0 9 8 7 6 ...

Страница 125: ...multifunction meter and handlebar switch 9 Wiring harness 1 Electrical box to base assy 10 Fuse holder fuse spare fuse 1 1 1 11 Screw 2 ø6 16 mm 12 Holder 1 13 CDI unit 1 14 Bolt 2 M6 10 mm 15 Starter motor cable 1 Starter relay to starter motor 3 N m 0 3 kgf m 2 2 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 15 N m 1 5 kgf m 11 1 ft...

Страница 126: ...ø6 30 mm 22 Spark plug wire 1 spark plug cap 1 1 23 Spark plug wire 2 spark plug cap 1 1 24 Ignition coil assy 1 25 Electrical box case 1 26 Nut 4 27 Bracket 1 28 Band 2 29 Battery breather hose 1 30 Battery 1 31 Battery box 1 3 N m 0 3 kgf m 2 2 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 17 N m 1 7 kgf ...

Страница 127: ...r È To base assy É To multifunction meter engine start switch and engine stop switch Ê To thermoswitch Ë To positive battery terminal Ì To starter motor B Black Br Brown G Green O Orange P Pink R Red W White Br W Brown White W R White Red 1 2 5 4 3 È É Ê Ë Ì 5 1 4 6 1 Br W W R B R O P W G B B R Br O G P B Electrical box ...

Страница 128: ...ction and corro sion and check that the battery is fully charged Use the peak voltage adapter with the rec ommended digital circuit tester Connect the positive pin of the peak voltage adapter to the positive terminal of the digital circuit tester and the negative pin to the negative terminal When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Ignit...

Страница 129: ... the engine connect the engine shut off cord to the engine shut off switch and then push the engine start switch and engine stop switch simultaneously CDI unit resistance 1 Measure the CDI unit resistance 2 Replace the CDI unit if out of specifica tion Ignition tester Spark gap tester 90890 06754 Primary coil resistance at 20 C 68 F reference data Connector Connector 0 078 0 106 Ω Secondary coil r...

Страница 130: ...he engine shut off switch and then push the engine start switch and engine stop switch simultaneously If measuring the charge coil output peak voltage under the Cranking and Unloaded conditions disconnect the charge coil terminals Charge coil resistance 1 Measure the charge coil resistance 2 Replace the charge coil if out of specifi cation È B W O B W R P Br W É B 10 40 0 150 600 3 11 2 6 W O B 0 ...

Страница 131: ... 1 Measure the pickup coil resistance 2 Replace the pickup coil if out of specifica tion Thermoswitch 1 Suspend the thermoswitch in a container filled with water and then slowly heat the water 2 Check the thermoswitch for continuity when the specified temperatures are reached 3 Replace if out of specification c No continuity d Continuity È Temperature É Time Pickup coil output peak voltage White R...

Страница 132: ...tance 1 Measure the lighting coil resistance 2 Replace the lighting coil if out of specifi cation Rectifier regulator Rectifier regulator output peak voltage 1 Disconnect the rectifier regulator connec tors 2 Measure the rectifier regulator output peak voltage 3 Measure the rectifier regulator resistance if below specification Lighting coil output peak voltage Green G Green G r min Unloaded Cranki...

Страница 133: ...handlebar switch assy if out of specification Engine stop switch continuity 1 Disconnect the left handlebar switch cou pler black coupler See Handlebar and handlebar switch assy 8 2 2 Check the engine stop switch for continu ity 3 Replace the left handlebar switch assy if out of specification È R B G1 G2 É R B 2 20 1 10 1 10 G1 1 10 2 15 3 30 G2 1 10 2 15 3 30 Engine start switch continuity Clip 1...

Страница 134: ...he positive battery lead to the terminal a and the negative battery lead to the terminal b 3 Check the continuity between the starter relay terminals 1 and 2 4 Replace the starter relay if out of specifi cation Starter relay continuity Battery lead a b Terminal 1 2 Disconnected No continuity Connected Continuity Br B 1 2 a b ...

Страница 135: ...t reusable 2 Bolt 2 M5 114 mm 3 Front cover assy 1 4 O ring 2 Not reusable 5 Washer set 1 6 Rear cover assy 1 7 Armature 1 8 Brush holder assy 1 9 Starter motor yoke 1 6 N m 0 6 kgf m 4 4 ft Ib A A A A 6 5 2 9 4 4 7 8 5 3 1 5 N m 0 5 kgf m 3 7 ft Ib Starting system Starter motor ...

Страница 136: ...sembling it 4 Disconnect the negative battery cable and then the positive battery cable from the battery terminals Armature Armature appearance 1 Check the armature Replace if damaged or worn 2 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty Commutator diameter 1 Measure the commutator diameter a Replace the armature if below specifica tion Commutator undercut 1 Meas...

Страница 137: ...eplace if out specification Starter motor assembly Do not reuse an O ring always replace it with a new one 1 Install the brush holder assy 1 and then tighten the nut a to the specified torque Armature continuity Commutator segments a Continuity Segment a Armature core b No continuity Segment a Armature shaft c No continuity Brush length a 6 5 12 5 mm 0 26 0 49 in a Brush holder assy continuity Bru...

Страница 138: ...re is no continuity 6 Replace the multifunction meter if there is continuity Hour meter operation 1 Check the hour meter display 2 Replace the multifunction meter if it does not operate correctly Oil level sensor and oil level warning indicator 1 Check the oil level sensor if oil level warning indicator does not come on 2 Replace the oil level sensor if out of specification 3 Replace the multifunc...

Страница 139: ...art the engine 3 Disconnect the thermoswitch connectors 1 and then connect the jumper lead to the disconnected connector 4 Check that the WARNING indicator light and the engine overheat warning indicator blink and the buzzer begins to sound intermittently Buzzer 1 Connect the positive battery lead to the terminal 1 and the negative battery lead to the terminal 2 2 Check that the buzzer sounds Repl...

Страница 140: ...ion meter and engine hatch cover 8 11 Steering master assy 8 13 Steering master 8 14 Shift lever assy check 8 15 Bushing check 8 15 Steering arm assy installation 8 15 Steering cable 8 16 Steering cable installation steering master end 8 17 Steering cable installation jet pump end 8 17 Seat and handgrip 8 18 Ventilation hose and water separator 8 19 Seat lock check 8 21 Check valve check 8 21 Wate...

Страница 141: ...1 2 3 4 5 6 7 8 9 A Deck and hull 8 25 Rear section 8 27 Drain plug check 8 29 Spout installation 8 29 ...

Страница 142: ...bar cover No Part name Q ty Remarks 1 Screw 2 ø4 10 mm 2 Screw 4 ø5 16 mm 3 Upper handlebar cover 1 4 Steering pad 1 5 Screw 4 ø6 14 mm 6 Lower handlebar cover 1 5 2 6 4 1 1 3 1 N m 0 1 kgf m 0 7 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib ...

Страница 143: ...tch assy 1 8 Bolt 2 M5 25 mm 9 Throttle lever assy 1 10 Bolt 4 M8 45 mm 11 Handlebar holder 2 a Punch mark 12 Handlebar 1 13 Grommet 1 14 Plastic tie 1 15 Left handlebar switch coupler 2 15 13 14 11 1 N m 0 1 kgf m 0 7 ft Ib 3 N m 0 3 kgf m 2 2 ft Ib 3 N m 0 3 kgf m 2 2 ft Ib 20 N m 2 0 kgf m 14 8 ft Ib 1 2 3 7 7 6 4 9 1 2 3 10 10 11 5 8 9 12 a Steering pad and handlebar cover Handlebar and handle...

Страница 144: ...throttle lever assy No Part name Q ty Remarks 1 Left handlebar switch assy 1 2 Engine shut off cord 1 3 Stop button assy 1 4 Start button assy 1 5 Screw 2 6 Throttle lever assy 1 7 E ring 1 8 Washer 2 9 Shaft 1 10 Lever 1 11 Spring 1 6 1 9 8 10 11 7 8 4 2 5 5 3 ...

Страница 145: ...r assy make sure that the throttle cable and left han dlebar switch lead are not pulled when the handlebar is turned to the right and left 1 Install the left handlebar switch lead 1 into the opening a in the grommet 2 and then install the throttle cable 3 into the opening a TIP Face the chamfered end b of the grommet 2 down with the opening a facing forward 2 Install the grommet 2 into the steerin...

Страница 146: ...fied torque TIP Align the projection f on the throttle lever assy with the handlebar hole g 5 Install the left handlebar switch assy 0 and then tighten the screws A to the specified torque TIP Align the projection h on the handlebar switch assy with the handlebar hole k 6 Install the throttle cable end into the throttle lever 7 Fit the seal m into the groove in the bracket 8 Pull the throttle cabl...

Страница 147: ...and then tighten the bolts G to the specified torque Steering pad and handlebar cover installation After installing the handlebar upper cover make sure that the throttle cable is not pulled when the handlebar is turned to right and left 1 Install the lower handlebar cover 1 and then tighten the screws 2 to the speci fied torque 2 Push the steering pad 3 into the upper handlebar cover 4 until it is...

Страница 148: ... lower handlebar cover 3 Install the upper handlebar cover 4 and then tighten the screws 5 and 6 to the specified torque TIP Align the portions a on the upper handlebar cover with the portions b on the lower han dlebar cover Upper handlebar cover screw ø5 16 mm 5 Upper handlebar cover screw ø4 10 mm 6 1 N m 0 1 kgf m 0 7 ft lb 3 4 5 4 6 a b b a ...

Страница 149: ...assy 1 9 Screw 8 ø5 15 mm 10 Front hood 1 11 Nut 2 12 Washer 2 13 Bolt 2 M6 95 mm 14 Ventilator cover 1 15 Packing 1 Not reusable 16 Bolt 4 M6 18 mm 12 17 11 13 18 19 15 7 9 16 5 2 2 1 1 6 8 10 3 4 14 2 N m 0 2 kgf m 1 5 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib Left handlebar switch assy and throttle lever assy Front hood ...

Страница 150: ...e Q ty Remarks 17 Hinge assy 1 18 Rivet 5 19 Service lid 1 12 17 11 13 18 19 15 7 9 16 5 2 2 1 1 6 8 10 3 4 14 2 N m 0 2 kgf m 1 5 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib ...

Страница 151: ...rivet hold the rivet flange a with both hands and push the rivet pin perpendicularly against a hard flat surface until the pin protrudes from the top of the rivet Hinge assy check 1 Fully open the front hood and check that it remains in the open position If the front hood cannot remain in the open position replace the hinge assy Hood lock check 1 Fully close the front hood and check that it latche...

Страница 152: ... 4 Center console box lid 1 5 Damper 2 6 Nut 6 7 Bolt 4 M6 18 mm 8 Bolt 4 M6 29 mm 9 Bolt 4 M6 29 mm 10 Plastic tie 1 11 Multifunction meter coupler 4 12 Engine hatch cover 1 13 Screw 4 ø5 15 mm 14 Multifunction meter 1 15 Spring nut 4 6 6 6 9 8 19 18 14 13 11 15 7 12 5 5 7 3 3 2 4 17 16 8 1 10 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib ...

Страница 153: ... ty Remarks 16 Lid lock hook 1 17 Nut 2 18 Revet 1 19 Plug 1 6 6 6 9 8 19 18 14 13 11 15 7 12 5 5 7 3 3 2 4 17 16 8 1 10 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib Multifunction meter and engine hatch cover ...

Страница 154: ... Remarks 1 Buzzer coupler 1 2 Steering cable joint 1 3 Bolt 1 M6 18 mm 4 Cable stopper 1 5 Bolt 4 M8 30 mm 6 Steering master assy 1 7 Rivet 2 Not reusable 8 Cable stopper bracket 1 9 Grommet 1 5 6 7 N m 0 7 kgf m 5 2 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 1 9 2 8 7 7 8 4 3 ...

Страница 155: ...assy 1 8 Bushing 1 9 Band 2 Not reusable 10 Buzzer 1 11 Bolt 2 M5 16 mm 12 Bracket 1 13 Bolt 4 M6 25 mm 14 Case assy 1 15 Packing 1 Not reusable 16 Housing assy 1 1 2 3 4 5 6 4 N m 0 4 kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 16 N m 1 6 kgf m 11 8 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 8 16 11 10 15 9 13 14 12 10 7 N m 0 7 kgf m 5 2 ft Ib Steering master assy Steering master ...

Страница 156: ...amaged or worn Steering arm assy installation 1 Install the steering arm assy 1 nut 2 and plate 3 and then tighten the bolt 4 to the specified torque TIP Align the projection on the steering shaft assy with the slot on the arm Align the tab a on the plate 3 with the por tion b on the steering arm assy 1 Bend a tab c along a flat side of the bolt Steering arm assy bolt 4 16 N m 1 6 kgf m 11 8 ft lb...

Страница 157: ... 8 18 Ride plate rubber plate See Intake grate and ride plate 6 1 1 Steering cable joint 1 2 Bolt 1 M6 18 mm 3 Steering cable stopper 1 4 Plastic tie 3 5 Nut 1 6 Steering cable 1 7 Packing 1 Not reusable 5 4 7 6 1 2 3 7 N m 0 7 kgf m 5 2 ft Ib 5 9 N m 0 59 kgf m 4 4 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib Steering master Steering cable ...

Страница 158: ...the groove a in the outer cable 2 Connect the steering cable joint 4 to the ball joint 5 3 Adjust the steering cable See Jet thrust nozzle steering angle check 3 7 Steering cable installation jet pump end 1 Adjust the steering cable set length a and then tighten the locknut 1 to the specified torque jet pump end Steering cable stopper bolt 3 7 N m 0 7 kgf m 5 2 ft lb 1 2 3 a 4 5 Steering cable set...

Страница 159: ...2 M6 40 mm 3 Seat lock assy 1 4 Packing 1 Not reusable 5 Nut 1 6 Washer 1 7 Projection 1 8 Washer 1 9 Nut 4 10 Washer 4 11 Bolt 4 M8 30 mm 12 Handgrip 1 3 1 11 2 4 7 8 12 10 9 6 5 5 N m 0 5 kgf m 3 7 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib Steering cable Seat and handgrip ...

Страница 160: ...tion box 2 3 Band 2 Not reusable 4 Ventilation hose 2 5 Grommet 2 6 Nut 2 7 Seat holder 1 8 Band 3 Not reusable 9 Fuel tank breather hose 1 1 10 Fuel tank breather hose 2 1 11 Rivet 2 Not reusable 12 Water separator 1 13 Rivet 1 Not reusable 14 Filter bracket 1 19 20 22 21 23 18 6 9 12 10 3 4 3 4 8 2 1 15 1 16 17 5 5 7 14 2 13 11 24 26 27 25 8 8 È 15 N m 1 5 kgf m 11 1 ft Ib 4 N m 0 4 kgf m 3 0 ft...

Страница 161: ...t reusable 21 Clamp 1 22 Cooling water pilot outlet 1 23 Cooling water hose 1 È To exhaust joint 24 Plastic tie 1 25 Band 1 Not reusable 26 Check valve 1 27 Oil tank breather hose 1 19 20 22 21 23 18 6 9 12 10 3 4 3 4 8 2 1 15 1 16 17 5 5 7 14 2 13 11 24 26 27 25 8 8 È 15 N m 1 5 kgf m 11 1 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib Ventilation hose and water separator ...

Страница 162: ...e fuel tank breather hose 1 1 2 Disconnect fuel tank breather hose 1 1 and fuel tank breather hose 2 2 Water separator check 1 Check the water separator 1 O ring 2 and drain plug 3 Replace if cracked or damaged Water separator assy installation 1 Connect fuel tank breather hose 1 1 and fuel tank breather hose 2 2 onto the water separator 3 TIP Connect fuel tank breather hose 1 1 which is identifie...

Страница 163: ...ll the ventilation hoses 3 TIP Make sure to route the ventilation hose PORT in front of the ventilation hose STBD Make sure that the end of the ventilation hose 3 is the specified distance a from the groove around the outside of the grom met 1 Cooling water pilot outlet nut 3 4 N m 0 4 kgf m 3 0 ft lb 3 1 2 b a 1 1 2 2 Installation distance a 30 40 mm 1 18 1 57 in 3 2 2 a 1 3 Ventilation hose and ...

Страница 164: ...e Intake grate and ride plate 6 1 1 Band 1 2 Clamp 3 3 Water lock 1 4 Band 1 Not reusable 5 Rubber hose 1 6 Bolt 3 M5 20 mm 7 Exhaust outlet 1 8 Band 1 Not reusable 9 Hose 1 10 Seal 1 Not reusable 5 4 10 2 7 9 8 2 3 1 2 6 6 LT 572 LT 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib ...

Страница 165: ...8 24 1 2 3 4 5 6 7 8 9 A Exhaust system check 1 Check the rubber hoses Replace if burned cracked or damaged 2 Check the water lock Replace if cracked damaged or leaked Exhaust system ...

Страница 166: ... mm 2 Bow eye 1 3 Nut 4 4 Washer 4 5 Bolt 2 M6 25 mm 6 Front protector 1 7 Bolt 2 M6 25 mm 8 Rivet 9 Not reusable 9 Rear protector 2 10 Inner gunwale 2 11 Rivet 30 Not reusable 12 Washer 30 13 Side gunwale 2 14 Bolt 10 M8 40 mm 1 2 7 5 19 6 11 4 4 3 12 3 13 17 10 16 15 14 8 9 8 7 N m 0 7 kgf m 5 2 ft Ib 13 N m 1 3 kgf m 9 6 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 20 18 ...

Страница 167: ...llar 10 16 Sponson 2 17 Rivet 2 Not reusable 18 Fuel cock cover 1 19 Rivet 2 Not reusable 20 Choke cover 1 1 2 7 5 19 6 11 4 4 3 12 3 13 17 10 16 15 14 8 9 8 7 N m 0 7 kgf m 5 2 ft Ib 13 N m 1 3 kgf m 9 6 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 20 18 Deck and hull ...

Страница 168: ... 1 Nut 2 2 Bracket 1 3 Plate 2 4 Ski tow 1 5 Clamp 1 6 Spout hose 1 7 Nut 1 8 Spout 1 9 Nut 4 10 Plate 4 11 Packing 2 Not reusable 12 Stern eye 2 13 Nut 4 14 Washer 4 5 8 7 15 9 10 12 10 11 4 3 1 2 3 17 16 14 13 2 N m 0 2 kgf m 1 5 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 6 BOW ...

Страница 169: ...Screw 4 ø5 25 mm 16 Packing 2 Not reusable 17 Drain plug 2 5 8 7 15 9 10 12 10 11 4 3 1 2 3 17 16 14 13 2 N m 0 2 kgf m 1 5 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 6 BOW Rear section ...

Страница 170: ...amaged Spout installation 1 Install the spout 1 and then tighten the nut 2 to the specified torque 2 Install the hose 3 and then tighten the clamp 4 to the specified torque TIP Face the mark a toward the bow Spout nut 2 5 N m 0 5 kgf m 3 7 ft lb Spout hose clamp 4 2 N m 0 2 kgf m 1 5 ft lb 1 2 4 1 a 2 3 BOW ...

Страница 171: ...TRBL SHTG 1 2 3 4 5 6 7 8 9 A Troubleshooting Engine unit troubleshooting 9 1 Troubleshooting engine unit jet pump unit charging system 9 1 ...

Страница 172: ...cking step See page Starter motor does not operate Discharged battery Check the battery voltage and spe cific gravity 3 8 Loose connection of bat tery terminal Check the battery cable and termi nal for proper connection 7 2 Blown fuse Check the fuse for continuity 7 10 Starter relay malfunction Check the starter relay 7 11 Engine start switch mal function Check the engine start switch left handleb...

Страница 173: ...k the wiring harness WD Spark plug does not spark all cylinders Engine shut off cord clip not installed Check that the engine shut off cord clip is installed properly 7 10 Engine stop switch mal function Check the engine stop switch left handlebar switch 7 10 Pickup coil malfunction Measure the pickup coil output peak voltage 7 8 Measure the pickup coil resistance 7 8 Short open or loose con necti...

Страница 174: ...ymptom 2 Cause Checking step See page Throttle valve does not move properly Throttle cable installed incorrectly Adjust the throttle lever free play 3 2 Throttle valve malfunction Check the throttle valve synchroni zation 4 15 Improper throttle stop screw setting Adjust the throttle stop screw 3 6 Spark plug does not spark some cylin ders Spark plug malfunction Check the spark plug 3 4 Ignition co...

Страница 175: ...ng water passage Check the cooling water pilot outlet for water discharge Check the cooling water passage 2 13 Thermoswitch malfunction Check the thermoswitch 7 8 Symptom 2 Cause Checking step See page Battery performance decrease Check the battery voltage and spe cific gravity 3 8 Loose connection of bat tery terminal Check the battery cable and termi nal for proper connection 7 2 Short open or l...

Страница 176: ... pump unit malfunction Check the impeller impeller duct and intake grate 6 6 Water entered hull Check the drain plugs and O rings for damage 8 29 Check the cooling water hoses for damage 2 13 Check the water lock and rubber hoses for damage 8 24 Check the exterior of the hull for damage Check the bilge hose bilge strainer and joint 3 9 ...

Страница 177: ...1 2 3 4 5 6 7 8 9 A Appendix Wiring diagram A 1 ...

Страница 178: ...level sensor L Blue 5 Fuel level sensor O Orange 6 Multifunction meter P Pink 7 Buzzer R Red 8 Engine start switch W White 9 Engine shut off switch Br W Brown White 0 Engine stop switch L B Blue Black A Battery L R Blue Red B Starter relay W L White Blue C Fuse 10 A W R White Red D CDI unit E Rectifier regulator F Ignition coil G Spark plug A 1 ...

Страница 179: ......

Страница 180: ...YAMAHA MOTOR CO LTD Sep 2010 1 CR E ...

Страница 181: ... B W L B W L B L R L B W L B B G R P B Br B W B W R G R P B P B O B R B G G B P P G G G P P O B O B B P B Br W W R G G B Br W W R G G B B W W W P O B B B B B B B B B B Br W W R Br W W R G G B R R Br B W R R R B R R R Br Br R R R R R R Br B B W Br R B W Br Br L R L B B R 10A ...

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